Method and apparatus for wire winding

ABSTRACT

Wire-wound memory devices or like articles are automatically manufactured by securing an end of the wire to a desired point on the apparatus and then drawing wire from the end of a narrow feeder tube which is held in a fixed position as a result of controlled movement of the device or article to be wired with respect to the end of the feeder tube. The device to be wired is mounted on an X-Y table for such controlled movement, and the X-Y table is moved in accordance with a program carried on and automatically read from a tape, which also is used to automatically control a soldering head and a wire-tamping apparatus so that the wire can be soldered automatically at desired points during the winding program and periodically tamped into a neat and compact winding configuration.

United States Patent [72] Inventors Gino Venturi Ann Arbor;

John F. Stankey, Inkster, both of Mich. [21] Appl. No. 24,500 [22] Filed Apr. 1, 1970 [45] Patented Dec. 28, 1971 [73] Assignee Sycor, Inc.

Ann Arbor, Mich.

[54] METHOD AND APPARATUS FOR WIRE WINDING 21 Claims, 5 Drawing Figs.

[52] US. Cl 29/604 [51] Int. Cl I-I0lf 7/06 [50] Field of Search 29/604 [56] References Cited UNITED STATES PATENTS 3,174,214 3/1965 Davis 29/604X 3,440,719 4/1969 Meier ABSTRACT: Wire-wound memory devices or like articles are automatically manufactured by securing an end of the wire to a desired point on the apparatus and then drawing wire from the end of a narrow feeder tube which is held in a fixed position as a result of controlled movement of the device or article to be wired with respect to the end of the feeder tube. The device to be wired is mounted on an X-Y table for such controlled movement, and the X-Y table is moved in accordance with a program carried on and automatically read from a tape, which also is used to automatically control a soldering head and a wire-tamping apparatus so that the wire can be soldered automatically at desired points during the winding program and periodically tamped into a neat and compact winding configuration.

PAYENTED UECZ 8 197] SHEET 2 [IF 2 SOLDER MOVE SUPPORT I3 WIRES TAMP DOWN ACTWATE SOLDERING HEAD 31 ACTIVATE X MOTOR \4 ACTIVATE Y MOTOR 15 ACT \VATE COMB. MOTOR 45 GENERATE AND S\GNALS READ FROG RAM S r m? 6 KQ U muw f a VA 0 2. v F w/ 4 M5, e

METHOD AND APPARATUS FOR WIRE WINDING BACKGROUND OF THE INVENTION This invention relates to a method and apparatus for winding or threading wire in particular intricate patterns about any number of bobbins or like members carried upon a supportive element, for example a circuit board or the like, to which the wires may be soldered. The bobbins may include such mem- O tabs. For example, in a particular embodiment of the invention a read-only memory page is comprised of a board carrying 256 eight-bit words, in which sixty-four wires are wound about sixteen paths and sixteen posts. Each wire may contain four words.

In the past, the wires in such devices have been wound only by hand, whereas functionally analogous braided memories have been woven by modified weaving apparatus. In the latter, the wire is first wound onto a loom and then woven by a plurality of programmed weaving rods, but this operation equires an oper agor who must place temporary separators between wires which have been separated by the weaving rods. The resulting woven pattern is then assembled onto cores, which are substituted for the temporary separators. This assembly is then incorporated into memory modules.

SUMMARY OF THE INVENTION The present invention obviates the difficulties which have been previously encountered in winding wire onto bobbins on a wire-carrying or like board. In a preferred embodiment, the

invention comprises a support, and a means for securing the carrier board on the support, together with a means for feeding wire r moving the support in a predetermined pattern of movements with respect to the wire-feeding means, such that wire is wound around the bobbins on the carrier board in accordance with a predetermined program.

The wire is wound or threaded automatically, and precisely in accordance with a predetermined path configuration; thus, the need for operator participation is minimized to the point of substantial elimination. The apparatus is relatively simple in construction and hence can be economically acquired. Thus,

it is one object of this invention to minimize costs in both labor and equipment in the manufacture ofsuch wired devices.

It is a major object of this invention to provide a system whereby the operation of the apparatus is programmed in advanced, such that operator errors are minimized. Once the operations program is established, an indefinite amount of repetition is possible without the inherent error attendant operation by a human being.

It is a further object of this invention to provide for automatic wire winding, and also provide for automatic tamping of wire wound onto the board, and for automatic soldering of the wire to the board at desired intervals. These provisions effectuate further economies in labor and also further insure the minimization of error.

BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other aspects and objects of the invention can be seen by reference to the specification and to the appended drawings, wherein:

FIG. I is a perspective view of the overall apparatus, with the exception of the readout assembly;

FIG. 2 is an enlarged side elevational view of the readout as- 5 sembly used in the apparatus of FIG. 1;

FIG. 2a is an enlarged fragmentary side elevational view of a portion of the readout assembly of FIG. 2;

FIG. 3 is a fragmentary perspective view of a carrier board mounted on the support; and

FIG. 4 is an operational flow diagram of the apparatus and showing the process of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT The basic components of the invention are shown in FIGS. 1 and 2 and include an X-Y table assembly 10 (shown somewhat pictorially), wire feed assembly 20, soldering assembly 30, comb assembly 40, and tape readout assembly 50. These components act in combination to wind wire from spools 25 onto a carrier board 60, such as that shown in more detail in FIG. 3.

Table assembly 10 includes a supporting frame 11 which can be constructed in any conventional manner. Movably mounted thereon is a first stage or X stage 12, comprising basically a carrier plate. X-stage 12 is in threaded engagement with a lead screw 16 which is rotatably carried at one end by a mount 18 supported on frame 11. At its other end, lead screw 16 is connected for rotation to an X-motor 14, which is also mounted on frame 11, Movably mounted on X-stage I2 is a second stage or Y-stage, comprising another carrier plate 13. Y-stage 13 is threaded on a Y-Iead screw 17 which is rotatably carried at one end by a mount 19 mounted on X-stage 12. At its other end, Y-screw 17 is connected for rotation to a Y- motor 15, which is also mounted on X-stage 12. The X- direction motor 14 and the Y-direction motor 15 can be conventional step motors operate for a specific angular displace ment in response to an impulse signal. As will be appreciated by one skilled in the art, other types of drive motors can also be utilized, with actuation by appropriate analogue signals of the functions to be performed. It is, of course, preferable that there be practically no unpredictable coasting in the motors, which might cause X- or Y-stage movement other than that specifically commanded.

FIG. 1 shows two of the wire feed assemblies 20 mounted on frame 11, for simultaneously winding a pair of the boards 60. In principle, any number of wire feed assemblies 20 can be mounted on frame 11, for simultaneous manufacture of a similar number of boards, provided that table assembly 10, including X-stage l2 and Y-stage 13, is sufficiently large.

Each wire feed assembly 20 includes a feed tube 21 having a lower end extremity positioned immediately adjacent the top surface of Y-stage 13 which, as will be shown latter, provides a support for carrier board 60. Feed tube 21 is a stiff tubular member and extends from just above and adjacent Y-stage l3 upwardly to a support arm 22, to which it is mounted. Support arm 22, in turn, is mounted on frame 11. Arm 22 extends upwardly from frame 11, and then outwardly over Y-stage 13. A piece of flexible tubing 23 extends from the open upper end of feed tube 21 rearwardly to a position adjacent the wire spools 25, which are removably mounted on frame 11. Wire wound on spool 25 passes upwardly through tubing 23 and down throughfeed tube 21.

For each wire feed assembly 20, there is a soldering assembly 30 which is also mounted on the end of support arm 22, adjacent the feed tube 21. Soldering assembly 30 comprises a head 31 and a pair of arms 32 extending downwardly and inwardly from head 31. Soldering tips 33 are mounted on the lower ends of arms 32. Head 31 includes a conventional solenoid device or the like such that when activated, the arms 32 and soldering tip 33 are moved downwardly to engage tip 33 with the surface of a carrier board 60 mounted on Y-stage 13.

For each wire feed assembly and soldering assembly there is a comb assembly (FIG. 1) which is mounted on Y- stage 13. These assemblies comprise an openwork plate 41 disposed adjacent each of the carrier boards 60 and secured to an axle 44, which is rotatably mounted in axle mounts 47 secured to Y-stage 13. As illustrated, the axle 44 may be common to both plates 41. The plates 41 may be comprised of a plurality of wirelike fingers 43 (FIG. 3) which are held in rigid parallel relationship by connector strips 48 which are integrally secured thereto. Thus, between the tamping fingers 43 and connector strips 48 there are a plurality of apertures 42.

Common to all comb assemblies 40 is a motor 45, which is also mounted on Y-stage 13. A linkage 46 connects the drive shaft of motor to axle 44, such that activation of motor 45 causes axle 44 to rotate. This in turn forces the tamping fingers 43 downwardly into engagement with a carrier board 60 mounted on the surface of Y-stage 13.

All of the components heretofore described are automatically operated by means of the readout assembly 50 (FIG. 2). Commands for operating X-motor 14 and Y-motor 15, soldering head 31, and tamping motor 45 are programmed onto tape 51, which may be perforated paper tape of a well-known nature. Tape 51 is carried on reels 52 and passes over a pair of spring-loaded or weighted idler wheels 53 which serve to maintain proper tape tension and facilitate steady tape movement. A group of parallel star wheels 54 ride on and are rotated by perforations in tape 51 as the latter passes over a central idler wheel 53a. Each of the star wheels 54 is mounted on the end of the lever 55 (FIG. 2a) which pivots about a pin 55a. A leaf spring 56 for each of the star wheels is mounted at one end on a spring support 59, with the opposite end of the spring engaging the underside of lever 55, such that the star wheel is biased into engagement with idler wheel 53 and against tape 51 as it passes over idler wheel 53. Also engaging the end of lever 55 is a contact wire 57, which is itself constructed of a conducting spring material such as spring steel. Contact wire 57 is also mounted at one end on spring support 59, closely adjacent spring 56. As stated previously, there are a plurality of such star wheel assemblies, e.g., wheel 54, lever 55, spring 56 and wire 57, mounted adjacent one another on readout assembly 50. Thus, tape 51 can be programmed to command several different devices, as will be appreciated by one skilled in the art.

Tape 51 is programmed by punching holes therein at appropriate positions. When a lobe of a star wheel 54 engages such a hole (FIG. 2a it will drop into the latter, thereby allowing the star wheel to move downwardly, whereupon the opposite end of its supporting lever 55 will move upwardly. This will allow contact wire 57 to also move upwardly to engage a contact screw 58. This completes a path for a control signal in accordance with which the components heretofore described can be operated through control circuitry (which may be of well-known or state of the art characteristics) housed, for example, in the readout assembly chassis or housing and suitably connected to the basic apparatus illustrated in FIG. 1. In operation, a carrier board 60 is secured in position upon Y-stage 13, which acts as a support therefor. As will be understood, the board must, be secured such that it is not free to move with respect to Y-stage 13; however, that is not particularly difficult to accomplish, as will be appreciated, since any of a number of clamping or edge-clipping devices may be used with satisfactory results. A number of carrier boards 60 can be so mounted, with one such board for every wire feed assembly 20 which is available to wind wire thereon. However, even where a plurality of wire feed assemblies 20 are available, a lesser number of carrier boards 60 may be mounted on Y-stage 13 without having to deactivate the unused wire feed assemblies 20.

With carrier board 60 in place, the end of wire 25 is soldered or secured st some desired point on the carrier board. Tape 51 is programmed with a series of commands for operating X-motor l4 and Y-motor 15 at desired intervals for desired lengths of time or increments of motion, with the ultimate result being movement of the carrier boards through a sequence of X-Y motions.

As shown in FIG. 4, readout assembly 50 first reads" the program from tape 51 and generates command signals which activate X-motor 14 or Y-motor 15, or (if desired) both simultaneously. As Y-stage 13 moves along its predetermined path in accordance with commands from readout assembly 50, it pulls the wire through feed tube 21 to unwind the wire from spool 25. Thus, the wire is pulled from the end of the feed tube and wound around the various bobbin members on the carrier board, in this case I-cores 61 and terminal posts 62, which project upwardly from carrier board 60. The path of Y-stage 13 is programmed such that at certain intervals a carrier board 60 is positioned in direct alignment with plate 41, such that the apertures 42 of the latter are in alignment with I-cores 61 and posts 62. At this point, a command programmed onto tape 51 causes operation of comb assembly 40. That is, readout assembly 50 reads such command and generates a command signal whereby motor 45 is activated. This rotates plate 41 and its tamping fingers 43 downwardly into engagement with carrier board 60. The tamping fingers 43 act to force wire downwardly toward the surface of carrier board 60 and thereby insure a snug and compact winding about the l-cores 62. In this connection, the tamping action need not be, and in fact should not be, overly forceful or strong, and for this reason it is advisable to incorporate a frictional or other slip mechanism into the linkage 46, or between it and the motor 45 or the shaft 44. Also, it may be desired to program actuation of the motor such that the comb is reciprocated or oscillated a few times against the wire, rather than having only a single downward tamping action.

Once the wire is tamped down, the carrier board may again be moved by controlled activation of X-motor 14 and Y- motor 15, for example to a position such that wire feed tube 21 and soldering tip 33 are directly above a desired soldering tab 63. Tape 51 may have a programmed command such that when the board reaches this location it is momentarily held in position while readout assembly 50 reads a command for activation of soldering head 31. This brings soldering tip 33 downwardly into engagement with soldering tab 63 so that the wire is soldered to this tab. As will be appreciated, automated soldering heads of this type are known in the art and are commercially available. In such heads, the arms supporting the soldering tips are spring-loaded so that precise control of the tip motion or excursion is not necessary, and the tips are always under essentially the same pressure against the wires or like elements being soldered.

This sequence of operation can be repeated as often as desired and in any given sequence of motion and operation, until the desired winding configuration and soldered circuit connections are fully completed. Comb assembly 40 can be activated at any desired time and need not merely be a step which is performed prior to soldering. If soldering is to be infrequent, then it is desirable to activate comb assembly 40 several times between soldering steps.

Thus, it can be seen that this invention provides an essentially fully automated and completely accurate apparatus and method for winding wire onto a wire-carrying board or the like. Considerable economies in labor and in equipment are provided. Furthermore, a number of carrier boards can be wound simultaneously. Since readout assembly 50 and table assembly 10 comprise a major portion of the cost of the necessary apparatus, the ability to wind a plurality of boards using a single table assembly and a single readout assembly 50 is a very significant contribution. Finally, it is extremely important that this invention provides a system whereby all of the carrier boards so wound are identical when completed and wound with extreme accuracy, leaving much less chance of error than in situations where they have to be wound by hand or where a great deal of operator intervention is required.

It is entirely conceivable that upon examining the foregoing disclosure, those skilled in the art may devise embodiments of the concept involved which difier somewhat from the embodimerit shown and described herein, or may make various changes in structural details to the present embodiment. Consequently, all such changed embodiments or variations in structure which utilize the concepts of the invention and clearly incorporate the spirit thereof are to be considered as within the scope of the claims appended herebelow, unless these claims by their language specifically state otherwise.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.

1. An apparatus for winding wire onto bobbin elements carried on a carrier member, comprising: a support means, including means for mounting said carrier member in a predetermined position; a source of wire positioned adjacent said carrier member position; means for moving said support means and said positioned carrier member in a predetermined path with respect to said wire source to withdraw wire therefrom and thread such wire around the bobbin elements on said carrier member in accordance with said predetermined path.

2. The apparatus of claim 1 which includes: means responsive to a program of commands for activating said moving means in accordance with said commands.

3. The apparatus of claim 2, including a recorded program of said commands and means for reading said program.

4. The apparatus of claim 2 which includes means for soldering said wire to desired portions of said carrier member at predetermined intervals along said path in response to certain of said commands.

5. The apparatus of claim 2 which includes means for tamping said wire to compact the same at predetermined intervals along said predetermined path in response to certain of said commands.

6. The apparatus of claim 5 which includes means for soldering said wire to desired portions of said carrier member at predetermined intervals along said path in response to certain of said commands.

7. The apparatus of claim 1, wherein said support means includes means for mounting a plurality of said carrier members; and including an equal plurality of said wire sources each positioned adjacent the mounted position of a different one of said carrier members, such that wire can be withdrawn to each of said carrier members when said support means is moved through said predetermined path by said moving means.

8. An apparatus for winding wire onto portions of a wire carrier apparatus, comprising: means forming a support for such a carrier apparatus; means for supplying wire to said carrier from a fixed position closely adjacent that of such carrier on said support; first means for moving said support along one axis, and second means for moving said support in an axis perpendicular to such fist axis; means for reading a program of commands and for controlling said first and second moving means in accordance with said commands such that said wire issues from said supplying means as said support is moved along said predetermined path and is wound onto the bobbin members on said carrier in accordance with such path.

9. The device of claim 8 in which said means for supplying wire includes a generally rigid feeder member through which said wire passes.

10. The device of claim 8 in which said support-forming means comprises an X-Y table apparatus.

11. The device of claim 10 in which said means for supplying wire includes a generally rigid feeder member through which said wire passes, said member including a enerally tubular end portion disposed closely adjacent said -Y table apparatus.

12. The device of claim 11 which includes a means for soldering wire to said carrier; means for moving said soldering means into operative engagement with portions of said carrier when the same is in position on said table to solder wire to such carrier board portions; and means for activating said soldering means in accordance with programmed commands.

13. The device of claim 11 which includes a comb member positioned adjacent said carrier when the same is mounted on said table; and means for moving said comb into engagement with said carrier to tamp down wires wound on said carrier in response to a program of commands.

14. The device of claim 13 in which said comb member comprises a plurality of tamping fingers having spaces therebetween whose relationship to one another corresponds to the surface configuration of said carrier; said fingers being pivotally mounted with respect to said table on an axle disposed adjacent said carrier; said means for moving said comb comprising a motor and means coupling the same to said axle; said comb being rotated toward said carrier board when said axle is rotated by said motor.

15. A method for winding wire onto bobbins or like members carried on a carrier board, comprising; positioning the carrier board on a support; providing a source of wire; fixing one end of said wire to said carrier board; and moving said support to move said carrier board in a predetermined multidirectional path with respect to said source to withdraw said Wire from said source and wind the withdrawn wire onto the bobbins on said carrier board in accordance with said predetermined path.

16. The method of claim 15, in which said wire is withdrawn from said source through a slender elongated guide member which is held in a fixed position and which is of sufficiently small size as to fit between different ones of said bobbins, and in which said support is moved in a manner which moves such bobbins past and at least partially around said guide member.

17. The method of claim 16 which includes: moving said support and carrier board in response to a recorded program of commands.

18. The method of claim 17 which includes the step of actuating a soldering means in response to said program of commands in a manner to cause soldering of said wire to said carrier board at predetermined intervals along said predetermined path.

19. The method of claim 17 which includes the step of actuating a wire-tamping means in response to said program of commands in a manner to tamp said wire toward said carrier board at various predetermined intervals.

20. The method of claim 17 which also includes the steps of recording said program of commands, and reading the recorded program by use of automated detecting means.

21. A method for simultaneously winding wire onto spaced bobbins or like members on a plurality of carrier boards comprising the steps: providing a movable member; securing a plurality of carrier boards to said member; supplying wire to each of said carrier boards and fixing said wire to each such board; moving said member in a predetermined path to thread said wire around and onto the bobbins on each of said carrier boards in accordance with said predetermined path. 

1. An apparatus for winding wire onto bobbin elements carried on a carrier member, comprising: a support means, including means for mounting said carrier member in a predetermined position; a source of wire positioned adjacent said carrier member position; means for moving said support means and said positioned carrier member in a predetermined path with respect to said wire source to withdraw wire therefrom and thread such wire around the bobbin elements on said carrier member in accordance with said predetermined path.
 2. The apparatus of claim 1 which includes: means responsive to a program of commands for activating said moving means in accordance with said commands.
 3. The apparatus of claim 2, including a recorded program of said commands and means for reading said program.
 4. The apparatus of claim 2 which includes means for soldering said wire to desired portions of said carrier member at predetermined intervals along said path in response to certain of said commands.
 5. The apparatus of claim 2 which includes means for tamping said wire to compact the same at predetermined intervals along said predetermined path in response to certain of said commands.
 6. The apparatus of claim 5 which includes means for soldering said wire to desired portions of said carrier member at predetermined intervals along said path in response to certain of said commands.
 7. The apparatus of claim 1, wherein said support means includes means for mounting a plurality of said carrier members; and including an equal plurality of said wire sources each positioned adjacent the mounted position of a different one of said carrier members, such that wire can be withdrawn to each of said carrier members when said support means is moved through said predetermined path by said moving means.
 8. An apparatus for winding wire onto portions of a wire carrier apparatus, comprising: means forming a support for such a carrier apparatus; means for supplying wire to said carrier from a fixed position closely adjacent that of such carrier on said support; first means for moving said support along one axis, and second means for moving said support in an axis perpendicular to such fist axis; means for reading a program of commands and for controlling said first and second moving means in accordance with said commands such that said wire issues from said supplying means as said support is moved along said predetermined path and is wound onto the bobbin members on said carrier in accordance with such path.
 9. The device of claim 8 in which said means for supplying wire includes a generally rigid feeder member through which said wire passes.
 10. The device of claim 8 in which said support-forming means comprises an X-Y table apparatus.
 11. The device of claim 10 in which said means for supplying wire includes a generally rigid feeder member through which said wire passes, said member including a generally tubular end portion disposed closely adjacent said X-Y table apparatus.
 12. The device of claim 11 which includes a means for soldering wire to said carrier; means for moving said soldering means into operative engagement with portions of said carrier when the same is in position on said table to solder wire to such carrier board portions; and means for activating said soldering means in accordance with programmed commands.
 13. The device of claim 11 which includes a comb member positioned adjacent said carrier when the same is mounted on said table; and means for moving said comb into engagement with said carrier to tamp down wires wound on said carrier in response to a program of commands.
 14. The device of claim 13 in which said comb member comprises a plurality of tamping fingers having spaces therebetween whose relationship to one another corresponds to the surface configuration of said carrier; said fingers being pivotally mounted with respect to said table on an axle disposed adjacent said carrier; said means for moving said comb comprising a motor and means coupling the same to said axle; said comb being rotated toward said carrier board when said axle is rotated by said motor.
 15. A method for winding wire onto bobbins or like members carried on a carrier board, comprising; positioning the carrier board on a support; providing a source of wire; fixing one end of said wire to said carrier board; and moving said support to move said carrier board in a predetermined multidirectional path with respect to said source to withdraw said wire from said source and wind the withdrawn wire onto the bobbins on said carrier board in accordance with said predetermined path.
 16. The method of claim 15, in which said wire is withdrawn from said source through a slender elongated guide member which is held in a fixed position and which is of sufficiently small size as to fit between different ones of said bobbins, and in which said support is moved in a manner which moves such bobbins past and at least partially around said guide member.
 17. The method of claim 16 which includes: moving said support and carrier board in response to a recorded program of commands.
 18. The method of claim 17 which includes the step of actuating a soldering means in response to said program of commands in a manner to cause soldering of said wire to said carrier board at predetermined intervals along said predetermined path.
 19. The method of claim 17 which includes the step of actuating a wire-tamping means in response to said program of coMmands in a manner to tamp said wire toward said carrier board at various predetermined intervals.
 20. The method of claim 17 which also includes the steps of recording said program of commands, and reading the recorded program by use of automated detecting means.
 21. A method for simultaneously winding wire onto spaced bobbins or like members on a plurality of carrier boards comprising the steps: providing a movable member; securing a plurality of carrier boards to said member; supplying wire to each of said carrier boards and fixing said wire to each such board; moving said member in a predetermined path to thread said wire around and onto the bobbins on each of said carrier boards in accordance with said predetermined path. 